CONTENTS

Group Introduction 3
FPI at A Glance 4
The World Needs Pipe to Survive 4
Global Reach 5
From Past to Present 6
Global Pipe Demand 7
Industries We Serve 8
Technology Leadership 9
FPI’s Development 10

Product Range & Design Aspects 11

Fiberglass 12
Manufacturing 18
Product Range 22
Products 23
Jointing Systems 34
Design Aspects 36
Product Design Aboveground Pipe 37
Product Design Underground Pipe 39
Qalification Testing 40
System Design 46

Engineering Strategic Alliance Partnerships 50

Enoia 51
Dynaflow 56

Aspects of GRP Pipe System Design & Engineering 61

Case Studies 93
Ras Laffan Common Cooling Seawater System Phase II -
Category II Project 94
Barwa Commercial Avenue Pre-Insulated GRP Pipe System
for Chilled Water 101

Installation 106
Underground Piping System 107
Aboveground Piping System 135
Seawater Intake Outfall System 139
Oil & Gas System 147
Marine System 153

FIBERGLASS TECHNICAL OVERVIEW AND DESIGN ASPECTS

1
2
group introduction

The Future Pipe Industries Group (FPI) was established

in 1984 and is the global leader in the fiberglass pipe
industry, designing, manufacturing, and supplying
fiberglass pipe systems for customers throughout the world.
Headquartered in Dubai, the company’s operations include
nine factories and a global network of sales offices across
four continents.
FPI serves more than 300 customers in over 50 countries across the Water
Distribution, Industrial, Municipal & Infrastructure, Desalination & Power, Oil &
Gas, Petrochemical & Marine Application. Due to its global reach and strategic
locations, FPI is well positioned to take advantage of the increased demand for
fiberglass pipe worldwide.

As manufacturers of the world’s most comprehensive portfolio of fiberglass pipe

systems, with diameters as large as four meters, FPI has successfully promoted
fiberglass as a strong substitute to pipe systems fabricated with traditional
materials. This in line with the Group’s mission to maintain global leadership in
the fiberglass pipe industry and be recognized as the pioneer in the conversion
of world pipe demand into fiberglass.

3
FPI At A Glance

Vision: ‘To deliver water and energy to the world, in the most efficient way’

• Established in 1984, FPI is the global leader in the fiberglass pipe industry

• The Group has 9 factories, over 20 sales offices, 61 production lines and
4500+ employees globally

• FPI serve more than 300 customers in over 50 countries in the Water
Distrbution, Industrial, Municipal, Infrastruture, Desalination & Power, Oil &
Gas, Petrochemical and Marine Sectors

• Because of its global reach and strategic locations, FPI is well positioned to
take advantage of the increased demand for fiberglass pipe worldwide

THe World needs pipe to survive

• Pipes are the arteries and veins of nations carrying fluids that are the
lifeblood of civilization

• Developing economies are spending actively on new infrastructure

• Established economies such as Europe and North America have a pressing

need for pipe replacement

• The global pipe market is established at USD $186 billion in 2010

4
Global reach

5
 From Past to Present

FPI has developed significantly in the last three decades

FPI headquarters in Dubai, 1975

FPI headquarters in Dubai, 2002

6
Global Pipe Demand

Global pipe market overview

World pipe demand was estimated at $186bn in 2010, having
grown at an average of 10.6% per annum since 2001, compared to
13.6% per annum growth for fiberglass pipe

Global pipe market (2010)

World pipe demand
$186bn

World large diameter pipe demand

$127bn
68% of world pipe demand

World large diameter pipe demand addressable

by fiberglass pipe
$103bn
80% of world large diameter pipe demand

World fiberglass pipe demand

$4.5bn
5% of world addressable large
diameter pipe demand

Note: Large diameter pipe refers to pipe with diameters equal to or greater than six inches / 150mm.
Addressable pipe demand refers to potential demand for fiberglass pipe at current technology levels
Source: Freedonia

7
 Oil & Gas Water distribution Infrastructure & Municipal Industrial Petrochemical Desalination & Power

Examples
• Crude oil • Cross country • District cooling and • Cooling water • Brine disposal • Cooling water and
transmission transmission heating systems piping intake systems

• Flowlines • Irrigation • Irrigation networks • Fire mains • Chemical wells • Flue gas
desulphurization
• Injection lines • Municipal • Pipe rehabilitation • Industrial • Cooling water
distribution and slip lining manufacturing systems • Process and utility
• Marine vessel applications piping
piping • Potable water • Sewers • Fire-water systems

Key uses
• Industrial sewers • Salt water systems
• Refinery / offshore • Storm and surface • Process piping
Industries We Serve

platform piping drainage • Process piping

• Storage Tank • Urban fire-water • Storage tanks

networks
• Sub-sea piping
• Oil and gas • Governments • Governments • Industrial • Petrochemical • Governments
exploration companies (e.g. companies (typically
and production • Municipalities • Municipalities mining, dredging, downstream) • Power companies
companies sugar refineries,
• Utilities companies resin plants, etc) • Desalination

Key end-users
companies

8
TECHNOLOGY LEADERSHIP
• First to receive major accreditations - Received the first ever BSI
Kitemark award for GRP pipe systems

• Leader in developing proprietory technology -

Developed several core brands since 1984 (Wavifloat,
Wavistrong, Fiberstrong, Fibermar, Red Box and Yellow Box)

• Strategic technology acquisitions in the USA and Holland

• Sole ownership of technology

- Manage our know-how and
manufacturing technologies
- Do not license or share our know-how
and manufacturing technologies

• Extensive portfolio addressing many

end markets - providing single source
solutions

9
 FPI’s Development

I’S DEVELOPMENT
To date, FPI has produced enough pipe to circle the globe more
than three times.

date, FPI has produced enough pipe to make it more than three times round the earth’s ci

10
PRODUCT RANGE &
DESIGN ASPECTS

11
FIBERGLASS

COMPOSITE MATERIALS
Definition:
• 2 (or more) materials combined into 1
• Different properties
• Remain separate

Most Common:
• Strong & stiff fibers
• Flexible matrix

Examples:
• Wood
• Reinforced concrete
• Car tires Rubber

• Fiberglass Steel wire

Example of Composite: Car Tire

12
FIBERGLASS  HIGH PERFORMANCE MATERIAL OF CHOICE

BOEING 787
• 50% epoxy based composites
• body / wings / window frames
• < 10% steel

AIRBUS A380
• 25% epoxy based composites
• wings / bulkhead / tail / fuselage

13
ADVANTAGES OF FIBERGLASS

14
15
Water Distribution
Includes all pipe systems used in:
• Cross Country Transmission
• City Distribution
• Urban Development of Potable Water

Industrial
Includes all pipe systems that are used in:
• Dredging
• Mining (slurries)
• Sugar Refineries
• Resin Plants
• Aluminum Production Plants
• Cooling Systems and Fire Water for Industrial Facilities
• Process Piping and Other Industrial Manufacturing Applications

Municipal & Infrastructure

Includes all pipe systems for:
• Irrigation
• Storm Water
• Surface Drainage
• Sewer Networks
• Treatment Plant Piping
• Pumping Stations
• District Cooling & Heating

Desalination & Power

Includes all pipe systems that are within the premise of a power/desalination
plant such as:
• Salt Water Systems (intake and discharge outfall)
• Flu Gas Desulphurization (FGD)
• Process & Utility Piping

This sector includes pipe systems for the industrial, petrochemical and oil & gas
downstream sectors.

16
OIL & GAS APPLICATIONS
In the Oil & Gas market fiberglass pipe is used in a wide range of applications
including:
• Production Flow Lines and Gathering Systems
• Gas Gathering Systems
• Secondary and Tertiary Recovery Injection Systems
• Water Disposal Systems
• Chemical Disposal Wells
• Downhole Tubing for Injection and Production Wells
• Downhole Casing for Injection and Production Wells
• All Applications Subject to CO2 or H2S Contamination
• Offshore Platform Piping

Petroleum Downstream Process Sector

Includes all pipe systems that are used for downstream applications mainly in
processing units, refineries, gas plants, platforms and storage tanks.

The applications are mainly for circulation water, process piping, oily water,
cooling systems and fire fighting.

In addition to low pressure oil transmission, low pressure flow lines, floating
production storage and off-loading (FPSO).

Petrochemicals
Includes all pipe systems that are used within a petrochemical plant, such as
circulating water, process piping, chemical lines, cooling systems and fire water.

MARINE
FPI is a leading manufacturer and supplier of Glassfiber Reinforced Epoxy
Pipe Systems (GRE) to the marine markets since 1984. Due to their excellent
non corrosive characteristics, GRE pipe systems will last the lifetime of a ship.
Meeting the classification societies’ rules and IMO regulations, GRE systems are
specially designed for the use onboard of ships making it the material of choice.

17
MANUFACTURING

MANUFACTURING PROCESS

Helical filament winding Continuous filament winding

• Manufacturing machine consists • Computer controlled manufacturing

of rotating mandrel and a machine with a continuously
moving carriage that feeds the advancing mandrel, consists of
Machine raw materials onto the mandrel helical wound continuous steel band
Description • Precisely controlled through the and supported in a cylindrical shape
CNC program to achieve the by beams
required winding angle

• Winding of glass fiber rovings • Electronic sensors and computer

pre-impregnated with resin onto controlled metering allow precise
the mandrel to form the pipe application of raw materials resulting in
wall high quality product with consistency
Manufacturing • Pipe is cured • Pipe is cured
Process • Required lengths cut and ends • Required lengths cut and ends
calibrated calibrated
• Hydrotest and quality control • Hydrotest and quality control
inspection inspection

18
HELICAL FILAMENT WINDING (UP TO DN1600)

CONTINUOUS FILAMENT WINDING (UP TO DN4000)

19
Continuous Filament Winding of FIBERSTRONG® Pipe up
to 4000mm

Production Process - Pipes

20
Production Process - Fittings

Production Process - Prefabrication

21
PRODUCT RANGE

FPI - STANDARD CATEGORIES

• Glass Reinforced Polyester Resin System (GRP):
Medium Pressure (up to DN4,000 / 25 bar)

• Glass Reinforced Epoxy Resin System (GRE):

Medium Pressure (up to DN1,600 / 50 bar)

• Glass Reinforced Epoxy Resin System (GRE):

High Pressure (up to DN450 / 240 bar)

PRODUCT OFFERING SPECIFICATIONS

Overview of core offering
Diameter Range Pressure Range
Product Brand Temperature (oC)
(mm) (barg)
FRP pipe Fiberstrong 80 - 4,000 Up to 25 Up to 60 OC
Wavistrong H2O Wavistrong Up to 4,000 Up to 25 Up to 95 OC
HDPE pipe n/a 16 - 630 Up to 20 Up to 50 OC
Glass-reinforced
Fiberstrong Up to 4,000 Atmospheric (b) Up to 82 OC
tanks
Wavistrong Wavistrong 25 - 1,600 Up to 50 Up to 95 OC

22
PRODUCTs

Fiberstrong®

Can be used in a wide range of applications for both above and underground
installations. This is our Fiberglass Reinforced Polyester (FRP) product.

• The diameters range from 80mm to 4000mm

• Pressure classes are available up to 25 barg
• Maximum design temperature is 60 Celcius for polyester resin and 82
Celsius for vinylester resin
• Fiberstrong pipes are manufactured with a thermosetting polyester or
vinylester resin reinforced with fiberglass using the filament winding
technique and, occasionally, pure silica sand filler

Advantages:
• Relatively lightweight – low transportation cost
• Easy and rapid installation
• Durable under harsh conditions
• Anti-corrosive
• Requires minimal or no maintenance

23
GLASS REINFORCED POLYESTER (GRP): MEDIUM PRESSURE

FIBERSTRONG®

• Isophthalic or Vinylester Resin

• Diameters Range: DN 25 mm [1”] up to DN4000 mm [160”]
• Pressure Range: PN 3 barg [43 psi] up to PN 25 barg [363 psi]
• Jointing System: Double Bell Coupler, Lamination, Flange
• For Underground and Aboveground Installations
• Used In Cooling Water, Industrial Waste Water, Fire Water, Seawater Lines,
Sewerage & Drainage as well as Chlorination Lines.

PRE-INSULATED GRP PIPE FOR CHILLED WATER SYSTEMS

Fiberglass (GRP) Pre-Insulated Product Description.
Today, GRP (Glass Reinforced Plastics) non-corrosive piping materials have
become a well established replacement to steel in water, oil & gas and
industrial/petrochemical applications. This is mainly because of its non-
corrosive nature and reliability due to advances in manufacturing processes,
high quality raw materials and well established design, testing, and installation
standards.

24
GRP PIPES PRE-INSULATED - PRODUCT DESCRIPTION
1) The inner pipe or the carrier pipe is the pipe in contact with the chilled water
and is made of FPI’s FIBERSTRONG® Glassfiber Reinforced Polyester Pipes
which can be supplied in the diameter range of 25mm up to and including
2400mm, for different pressure classes.

2) The second component is the insulating material filling the annular space
between the carrier with pipe and the jacket liner. It is made of rigid closed
cell polyurethane foam, a very low thermal conductivity. It has a high
compressive strength and is dimensionally stable.

3) The third component is the jacket liner made of a thin GRP pipe on the
outside of the insulated pipe which provides the necessary protection to the
insulating foam.

Carrier Pipe (FIBERSTRONG® Fiberglass Pipe)

Insulating Material (Polyurethane Foam)

Jacket Liner (Thin Fiberglass Pipe)

25
WAVIstrong®

In the last 25 years, over 1000 miles of Wavistrong pipe systems have been
successfully installed throughout the world under the most corrosive and
demanding conditions.

• Applications include above and underground pipe systems as well as marine

and offshore
• This is our Glassfiber Reinforced Epoxy (GRE) pipe system
• Designed and qualified according to the major international standards such
as ASTM, Shell DEP, UKOOA, AWWA and ISO

Advantages:
• High chemical resistance
• Excellent mechanical properties
• Corrosion resistant
• UV resistant

26
GLASS REINFORCED EPOXY (GRE): MEDIUM PRESSURE

WAVISTRONG®
• Epoxy resin
• Diameters range : DN 25 mm [1”] up to DN1600mm [64”]
• Pressure range : PN 8 barg [116 psi] up to PN 50 barg [725 psi]
• For above and underground installations
• Jointing System : Adhesive Bonded Joint, Lamination, Rubber Seal Lock Joint,
Flange
• Used as utilities piping (e.g. fire fighting systems and oil & gas,
petrochemical & industrial applications & offshore applications

WAVISTRONG® H2O
A new system introduced for potable water applications

• The pipe, fitting and joint are GRE corrosion resistant pipe systems intended
for underground use
• Can be made available up to DN 4000 if needed and up to 25 barg
• It consists of a thermosetting chemical resistant epoxy resin and fiberglass
reinforcements

Advantages:
• Designed for a 50 year lifetime
• Lightweight
• Uses a variety of jointing systems
• Corrosion resistant
• UV resistant

27
GLASS REINFORCED EPOXY (GRE): HIGH PRESSURE

YELLOW BOX®
• Epoxy Resin
• Diameters range : DN 50 mm [2”] up to DN 450 mm [18”]
• Pressure range : PN 35 barg [500 psi] up to PN 240 barg [3500 psi]
• For above and underground Installations
• Jointing System : API Threaded Joint , Flange
• Used for oil & gas flow lines, gathering systems & injection systems

NEW DEVELOPMENT
Large Diameter Glass Reinforced Epoxy (GRE)

WAVISTRONG®
• Epoxy Resin
• Diameters range: up to DN4,000 mm
• Pressure range: PN 6 barg up to PN 25 barg
• Jointing System: Double Bell Coupler, Butt & Wrap, Flange
• For underground and aboveground installations
• Used in cooling water, industrial waste water, fire water, oily water,
sewerage and drainage lines

28
HDPE
High Density Polyethylene Pipes

• Diameters range from 16mm to 630mm as per DIN 8074/8075, ISO 4427
and EN 12201 in 50, 150 & 250 meter rolls depending on pipe diameter
• Pressure application is available up to 20 bar
• Joint type is Butt Fusion, Electrofusion or Compression fitting

Polyethylene is a versatile material having outstanding mechanical and chemical

properties. It is obtained by the polymerization of ethylene gas in varying
densities.

29
WAVI FLOAT

FIBERMAR PIPE SYSTEMS

Approved by:
• Bureau Veritas
• American Bureau of Shipping
• Lloyd’s Register of Shipping
• Det Norske Veritas (pending)

30
INTERMEDIATE SUMMARY PRODUCT RANGE
• Fiberglass
- Definition & advantages
• Manufacturing
- Helical & continuous
• Jointing Systems
- Different joints
- Non-restrained  restrained  hybrid systems
• Product Categories
- Standard ranges available
- New development – large diameter GRE; (up to DN4000)

Product Range
• Fiberglass
• Manufacturing
• Jointing Systems
• Product Categories

Design Aspects
• Design Process
• Pipe Design
• Qualification Testing
• System Design

31
QUALITY SYSTEM ACCREDITATIONS
TESTING AND QUALITY MANAGEMENT
• We have established a “Quality Management System” that applies to all
management, production and services offered at our various factories
globally
• We have our own long-term testing facility at our Abu Dhabi factory, used
to test new products for higher pressure, hire temperature and fire resistance
applications
• Every step of the manufacturing process at our factories, including raw
materials procurement, product inspection and testing, is routinely subjected
to inspection both internal and external by spot check and quality control
procedures
• Each of our factories is ISO certified

SELECTED ACCREDITATIONS
• American Bureau of Shipping (ABS)
• American Petroleum Institute (API)
• The British Standards Institution (BSI)
• Det Norske Veritas (DNV)
• Factory Mutual (FM)
• Industrial Research Institute (IRI)
• KEMA
• KIWA
• Lloyd’s Register Quality Assurance
• National Sanitation Foundation (NSF)
• TÜV Rheinland
• Universal Laboratories (UL)
• Water Regulations Advisory Scheme (WRAS)

32
SELECTED EXTERNAL AUDITORS
• BSI
• Bureau Veritas
• Factory Mutual
• M&T
• Mines de Douai
• NSF
• SFS Inspection Services
• Sintef
• TÜV Rheinland
• Underwriters Laboratories

ACCREDITATIONS

33
JOINTING SYSTEMS NON-RESTRAINED
JOINTS (Underground)

Double Bell Coupler Mechanical Coupler

RESTRAINED JOINTS (Above – and

Underground)

Laminated Joint Adhesive Bonded Flanged Joint

Joint

Rubber Seal Lock Threaded Joint

Joint

34
HYBRID SYSTEM CONCEPT(Restrained &
non-restrained joints in one system)
• Provides design flexibility to install fiberglass pipe systems without thrust
blocks
• Utilizes the soil friction, burial depth and other design parameters to
calculate the restrained length of the pipe
• Proven and reliable system even for low soil modulus values

Restrained joint
– laminated type

Non-Restrained joints –
Double Bell Coupler

Example of Hybrid System Concept

35
DESIGN ASPECTS

FPI DESIGN PROCESS

FPI’s Min.
Req. 1.PRODUCT DESIGN

Project Product Product U/G Technical

Tender Selection Design Tw Check Bid

PN, T, ø, Product Type & If needed

STIS, DLT, Joint System
Design
Spec, Joint, Allowables
UG/AG,, Product
Medium, Qualification
Q lifi ti
resin,
..... Long Term
2. QUALIFICATION
Testing Order
3. SYSTEM DESIGN TESTING

Production & Add. Reinf. Flex. / Stress

Construction (If needed) Analysis ISO’s

36
PRODUCT DESIGN - ABOVEGROUND PIPE

PRODUCT DESIGN – FOR WALL-THICKNESS

CALCULATION

• Pressure Calculation

• Stiffness Calculation

• Vacuum Calculation

PRODUCT DESIGN
• Pressure Calculation:

Where:
TEP = minimum reinforced wall thickness (mm)
PN = nominal pressure (MPa)
ID = inner diameter (mm)
SA = design stress (MPa)

• Stiffness Calculation:

Where:
TES = minimum reinforced wall thickness (mm)
Dm = pipe mean diameter (mm)
STIS = specific tangential initial stiffness (Pa)
Ehf = structural hoop flexural modulus (MPa)

37
• Vacuum Calculation:

Where:
If:

use

Otherwise use:

Where:
Rm = pipe mean radius (mm)
TEB = pipe structural wall thickness (mm)
Ѵ2 = product of both poison ratio
Dm = pipe mean diameter (mm)
PB = required buckling pressure (MPa)
SFb = buckling safety factor
EHF = structural hoop flexural modulus (MPa)
Lb = length between stiff ends (mm)

PRODUCT DESIGN - OUTPUT

Final
Nominal Final Str. Unreinf.
Pressure Calculation Stiffness Calculation Buckling Calculation Total
Diameter Thickness Thickness
Thickness

DN PN SA T EP STIS T HF T EIS T ES P b SF b L b E HF v2 T EB T E T L T C TW

mm Barg MPa mm Pa MPa mm mm Barg - mm MPa - mm mm mm mm mm

1,000 16.0 28.0 29.41 5,000 20,000 14.42 14.63 1.0 2.5 5,000 20,000 0.051 14.86 29.5 1.0 0.3 30.8
600 10.0 62.5 4.84 10,000 20,500 10.81 11.01 0.0 2.5 4,000 20,500 0.000 0.00 11.1 0.5 0.3 11.9

Pressure Stiffness
Governs Governs

38
PRODUCT DESIGN - UNDERGROUND PIPE

UNDERGROUND PIPE DESIGN

• Acts as a prediction model of pipe performance
• Guidance on the selection of soil properties and
compaction methods
• Guidance construction methods

AWWA
M45

Input: Output:
• Diameter (mm) • Deflection Prediction
• Pressure (bar) • Pressure effect
• Stiffness (Pascal) • Buckling analysis
AWWA
• Thickness (mm)
M45
• Burial depth (m) The calculation acts as a
• Wheel load (KN) prediction model of pipe
• Soil conditions performance.
• Backfill material

39
QUALIFICATION TESTING

Long Term Testing

• Strain corrosion test –ASTM D 3681
• Hydrostatic design basis - ASTM D 2992

Short/Medium Term Testing

• Hydraulic failure pressure of pipes and fittings ASTM D 1599
• Medium term survival test – ASTM D1598

Specific Test Methods

• Installation conditions
• Quality control test procedures
• Fire endurance
• Shock resistance

QUALIFICATION TESTING Hydrostatic Design Basis -

ASTM D 2992
• Pipes loaded and held until failure
occurs
• Failure points are statistically
analyzed  y50 years value
• Safety factor is applied
• > 18 samples are used for at least
10,000 Hrs (1.5 years)

40
LONG TERM QUALIFICATION TESTING
(ASTM D 2992 / D 3681)

LONG TERM QUALIFICATION TESTING

(ASTM D 2992 / D 3681)

41
LONG TERM QUALIFICATION TESTING
(ASTM D 2992 / D 3681)

LONG TERM QUALIFICATION TESTING

(ASTM D 2992 / D 3681)

42
LONG TERM QUALIFICATION TESTING
(ASTM D 2992 / D 3681)

LONG TERM QUALIFICATION TESTING

(ASTM D 2992 / D 3681

43
LONG TERM QUALIFICATION TESTING
(ASTM D 2992 / D 3681)

INTERPOLATION OF DESIGN STRESSES

(ASTM D 2992)

44
MEDIUM TERM TESTING
(as per ASTM D1598)

45
SYSTEM DESIGN

DESIGN ENVELOPE; STEEL VERSUS FIBERGLASS

large reservation for

axial stresses due to
bending, thermal
expansion, etc
1:1 load condition
Axial Stress, σA, [MPa]

no reservation for
axial stresses due to
bending, thermal
expansion, etc

Steel Pipe
2:1 load condition
(pipe under internal pressure) Fiberglass Pipe

Hoop Stress, σH [MPa]

FIBERGLASS DESIGN ENVELOPE (Construction)

46
FIBERGLASS DESIGN ENVELOPE (Example 1)

Increase wall
σAXIAL, BENDING thickness!

X Bending Moments

σAXIAL, PRESSURE

Axial Stress

Internal Pressure
2:1 load condition

Hoop Stress

σHOOP, PRESSURE Sf = 1.5

Increase wall
σAXIAL, BENDING thickness!

 Bending Moments
σAXIAL, PRESSURE


Axial Stress

Internal Pressure
2:1 load condition

Hoop Stress

σHOOP, PRESSURE Sf = 1.5

47
 FIBERGLASS DESIGN ENVELOPE (Example 2)

σAXIAL, BENDING

 Bending Moments

σAXIAL, PRESSURE

2:1 load condition

Internal Pressure
Axial Stress

Hoop Stress

σHOOP, PRESSURE Sf =1.5

Increase wall
thickness!

σAXIAL, BENDING
σAXIAL, PRESSURE
Axial Stress

2:1 load condition

Hoop Stress

σHOOP, PRESSURE Sf = 1.5

48
SUMMARY
• Product Range
- Advantages / Manufacturing / Joints
- Product Categories
• Design Aspects
- Product Design Process
- Pipe Design (A/G & U/G)
• Qualification Testing
- Long Term Testing
- Medium Term Testing
• System Design
- Design Envelop Construction & Use

49
ENGINEERING
STRATEGIC
ALLIANCE
PARTNERSHIPS

50
BEYOND ENGINEERING

Future Engineering is the Future Group’s specialist engineering services division.

The division’s primary subsidiary, ENOIA, is an integrated engineering

services company providing world-class project management, engineering,
procurement, construction management and supervision services across a broad
spectrum of Industrial, Oil & Gas and Infrastructure sectors.

51
ENOIA AT A GLANCE
ENOIA- Engineering of Industrial Applications - has provided engineering,
process design, consultancy and project management services to the Oil & Gas
and Petrochemical industries since 1987.

ENOIA is a multi-disciplinary engineering and project management corporation

with a proven track record of over 20 years in engineering excellence.

The Group today, has offices in Athens, Dubai, Abu Dhabi and Cairo.

ENOIA GROUP

ENOIA DYNAFLOW ENOIA ENOIA

Athens Dubai Abu Dhabi Egypt

OUR SERVICES
ENOIA provides a full spectrum of engineering services ranging from bespoke
professional advice to planning and engineering design for all phases of
industrial projects from the feasibility study and the conceptual design to plant
commissioning and start up.

52
Core services:
• Project management
• Consultancy
• Conceptual design, feasibility studies, initial project planning
• Basic design
• Safety studies
• Environmental studies
• Front end engineering design (FEED)
• Detailed engineering:
- Technological
- Machinery
- Piping
- Electrical
- Instrumentation
- Systems
- Civil
• Procurement services
• Construction management and supervision
• Commissioning and start up services

53
INDUSTRIES WE SERVE
ENOIA has over the past 20 years successfully managed high profile and large
scale projects in a number of industry sectors including:

• Oil & Gas / HPI

- Upstream facilities
- Pipelines
- Refineries
- Deports & loading/unloading terminals
• Desalination Plants
• Power Plants
• Minerals Processing Industry
• Other Industrial Projects
• Infrastructure Projects
- Water pipelines and pump stations
- Waste treatment plants
- Irrigation projects

54
COMMITMENT TO QUALITY
At ENOIA we provide services in compliance with customer requirements, either
specified or required, as well as with statutory and regulatory requirements.

ENOIA has a stringent Quality Management System (QMS) in place according

to ISO 9001:2008 requirements. The QMS provides the framework for the
operation and control of the activities affecting the product realization and
consequently, customer satisfaction.

55
Dynaflow International Inc.

www.dynaflowinternational.com

COMPANY PROFILE
Dynaflow International is a specialist consulting engineering company providing
integrated solutions for piping systems.

Dynaflow offices are located in Europe and the Gulf.

Dynaflow International is an ISO 9001:2000 certified company.

OVERVIEW OF CAPABILITIES
• (GRP) Pipe System Design
• Stress (static and dynamic) Analysis
• Hydrodynamic Effects and Earthquake Simulation
• Support Design (detailed, structural)
• Fitness for Purpose Analysis
• 3D Finite Element Calculations
• Hydraulic/Surge Calculation
• Vibration Analysis and Control, Forensic Analysis
• Design Auditing

56
DYNAFLOW CLIENTS
End users, EPC contractors, and consultants working in the following sectors:

• Petrochemical
• Chemical
• Oil & Gas treatment and production (onshore offshore)
• Water treatment
• Pipelines
• Municipal
• MEP contractors

DYNAFLOW EXPERTISE IN FIBERGLASS

• DFI possesses special expertise in the design of Large Bore fiberglass piping
systems (Epoxy /Polyester / Vinylester)
• DFI plays an active role in the introduction and further development of (new)
standards for fiberglass applications
(ISO-14692)

CURRENT STATE OF THE ART GRP EXPERIENCE

100

90

80
.

70 Pipe wallload P*D=2700

N/mm
Design Pressure [Barg]

Series3
60

50

40

30

20

10

0
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000
Nominal Diameter [mm]

57
TYPICAL APPLICATIONS
• Pumping Stations
• Flowlines
• Seawater (cooling water) Intakes/Outfall
• Plant Piping
- Power & Desalination Plants
- Petro-Chemical Plants
• Jacking Pipe Systems
• Fire Fighting (onshore & offshore)
• Pressure Vessels
• District Cooling / Chilled Water

PIPE SYSTEM DESIGN

Drawings
• General arrangement
• Profile
• Isometric drawings
• “As Built” status of system
• Support package
detailed drawings,
locations and functions
• Special requirements, fitting thickness,
puddle flanges, special rings etc.
• Pipe routing

ENGINEERING ASPECTS OF SINGLE POINT RESPONSIBILITY

• Design by analysis
• Fit for construction drawings
• Support package
• Verification of “as built” versus “as designed”

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DESIGN BY ANALYSIS
• Surge analysis
- Control of internal pressure / unbalanced forces
• Stress analysis
- Control of structural integrity
- Stress/strain in circumferential direction
- Stress/strain in axial direction

SUPPORT PACKAGE
• Support drawings, typical and specials
• Support attachments
• Spring selection
• Structural support design

VIBRATION PREDICTION & CONTROL

• Vibration measurement
• Pipe system modeling & computer simulation of the operating conditions for
static & dynamic load scenarios

System mechanical natural frequencies and measurements

100.00

90.00

80.00

70.00

60.00
Amplitude (dB)

50.00

40.00

30.00

20.00

10.00

0.00
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0
Frequency (Hz)

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ENGINEERING AUDITING

In-house
Dynaflow has the capability of auditing the pipe
system design and engineering, made by third
parties, by:

• Checking the design criteria

• Checking the process of design
• Validation of the output results

Site Check
Installation made according to the design output:
• Pipe system routing according to the
approved drawings
• Support system
(support locations and functions)
• Pipe material and jointing system

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ASPECTS OF GRP
PIPE SYSTEM
DESIGN &
ENGINEERING

61
SYSTEM DESIGN
• Stress Analysis
– Pipe stresses
– Support loads
– Displacements
– Equipment nozzle loads
• Surge Analysis
– Pressures
– Unbalanced forces
• GRE/ GRP pipe wall is flexible
• GRE/ GRP pipe expands due to pressure & temperature different from steel
• Pipe/ Fitting dimensions and properties different from metal
• GRE/ GRP pipe is orthotropic Axial and circumferential stiffness is different
• GRE/ GRP systems require dedicated supporting

PIPE WALL ELASTICITY PARAMETERS

• Ea Elasticity Modulus in Axial Direction
• Ec Elasticity Modulus in
Circumferential Direction
• Va/h Poisson Ratio Axial/Hoop
• Vh/a Poisson Ratio Hoop/Axial
• G Shear Modulus
Example of special property of GRP pipe
Maximum stress in pipe adjacent to bend not in bend

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MATERIAL PROPERTIESVARIATION FOR DIFFERENT SUPPLIERS

Supplier 1 Supplier 2 Supplier 3 Supplier 4

Lin exp 20 18 22 25 mm/mm/°C

Ec 20500 25000 17000 20000 MPa

Ea 11500 11000 8000 11000 MPa

νa/h 0.65 0.56 0.69 0.35

νh/a 0.38 0.37 0.39 0.2

ρ 1.85 1.85 1.55 1.85 *1000 kg/m3

COMPARISON BETWEEN METAL & GRP PIPE MATERIAL

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COMPARISON STEEL - GRP/GRE
Required free bend length for accommodation of expansion

Internal pressure: 20 Barg

Delta T: 60 degrees
Expanding leg: 50 m

Pipe Diameter GRE/GRP Steel

150 mm 7m 4m
200 mm 8m 4,6 m
250 mm 9m 5,2 m

PIPE LOAD ASSESSMENTS

• Pipe wall thickness for pressure containment (Internal and external)
• Pipe deflection (circumferential, lateral, axial)
- Material Elasticity
- Axial Direction
- Circumferential Direction
• Pipe Combined Strength (allowable stress)
- Axial Direction
- Circumferential Direction

BASIS FOR PIPE WALL STRENGTH

• Hydrostatic Design Basis (HDB) or LCL (95%)
- Long term hydrostatic hoop strength of pipe material
- 50 years or 20 years
- Typical value 120-125 MPa for GRE
• Regression tests
- ASTM D 2992 B

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SUMMARY OF IMPORTANT PIPE PROPERTIES TO BE ADRESSED IN
THE SYSTEM DESIGN
• Pipe expansion due to pressure
• Pipe expansion due to temperature
• Limited flexibility in bends
• Flexibility by geometry
• Stresses in bends and tees (fittings)

DESIGN BY ANALYSIS
• Surge Analysis
• Stress/Flexibility Analysis (Static & Dynamic)

SURGE ANALYSIS
Goal:
• Keep internal pressure within
allowables
• Determination of dynamic loads

Tools:
• Valve sizing & timings
• Surge devices

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SURGE ANALYSIS RECOMMENDED
• Pipes subject to unsteady flow
conditions
• Pipes connected to pumps
compressors, etc.
• Pipes with “fast” closing valves

• Pipes Subject to Two-Phase/Slug Flow

INFORMATION REQUIRED FOR SURGE ANALYSIS

• P&ID (piping and instrumentation diagrams)
• PFD (process flow diagrams)
• Drawings
• Equipment data sheets (pump curves)
• Operating philosophy
• Material properties
• Fluid properties

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SURGE ANALYSIS
• Review info (5%)
• Model system in BOS Fluids / Pipenet (25%)
• Run analysis (20%)
• Review results (30%)
• Issue report (20%)

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EFFECTS OF SURGE
• Column separation/ vacuum
• Pressure peaks
• Unbalanced forces (excessive movements)

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Finite Element Calculation of First Buckling Mode

72
FE calculation, First Buckling Mode Clipped Model

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MYTH ON SURGE CAPABILITY
• Compared to metal pipe Surge or Waterhammer effects are more violent in
GRP pipe ???
• Comparison Calculation
Upset condition:
Fast Valve Closure
Slow Valve Closure

PRESSURE DISTRIBUTION 15 SECONDS AFTER VALVE CLOSURE

VALVE CLOSURE TIME: 2 SECONDS
GRP Steel

PRESSURE TIME HISTORY AT VALVE CLOSURE TIME: 2 SECONDS

GRP Steel

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PRESSURE DISTRIBUTION 15 SECONDS AFTER VALVE
CLOSURE VALVE CLOSURE TIME: 15 SECONDS
GRP Steel

PRESSURE TIME HISTORY AT VALVE CLOSURE, 15 SECONDS

GRP Steel

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CONCLUSION FROM EXAMPLE
For the same upset condition, Surge / Water hammer pressure effects in GRP
pipe in general are less than in metal pipe !!!

VACCUM RESISTANCE
Depends on: Modulus of elasticity
Wall thickness / diameter
Length between ‘stiff’ ends

Increase by: Full vacuum pipe

Stiffener ribs
Vacuum breakers / surge vessels

STRESS / FLEXIBILITY ANALYSIS

Goal:
• Reduce material stresses
• Support/Flange/Nozzle loads due to:
- weight
- displacements
- internal/external pressure
- thermal expansion

Tools:
• Support arrangement (location & function)

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STRESS ANALYSIS REQUIRED
• Pipes > 2 “
- A/G & U/G Restrained systems
- U/G, combined (Non)Tensile Resistant -
- Tensile resistant in fittings (virtual anchor length)
- Pipes subject to large temperature difference
• Pipes subject to dynamic/surge conditions
• Pipes connected to strain sensitive equipment
• Design pressure above 1 barg

STRESS ANALYSIS NOT REQUIRED

• Pipes ≤ 2 “
• Non restrained joints (Double Bell Coupler)
• Design pressure below 1 barg (drains)
• System with anchor / thrustblocks

DATA REQUIRED FOR STRESS ANALYSIS

• Product data (wall thickness, lamination thickness, etc)
• Drawings / battery limits / limit of scope
• Allowable stresses (Stress envelope)
• Equipment data sheets (Allowable nozzle loads)

STRESS ANALYSIS
• Review info (5%)
• Split system in models
• Model system(s) in CAESAR II (15%)
• Run analysis (30%)
• Mark drawings
• Incorporate revisions (30%)
• Issue report (20%)

77
78
79
Check Stresses Caesar II Calculated Maximum Stress, model: FW001B

60 σqs = 125 MPa

σsa(0:1) = 65 MPa
σsh(2:1) = 250 MPa

50

40
Axial stress (MPa)

30

2:1 pressure
20

10

0
0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00 110.00 120.00 130.00
Hoop stress (MPa)

Long-term SUS Env. f2 = 0.67 OPE Env. f2 = 0.83 OCC Env. f2 = 0.89

80
81
STRESS ANALYSIS RESULTS
• Reinforcement of fittings (elbows / tees)
• Flexible material
• Anchors near pumps to reduce nozzle loads
• Re-routing

82
83
 Dedicated
Support

84
85
86
COMPLEX GEOMETRIES DESIGNED BY FE - METHODS

Pump House Manifold Ras Laffan Stress Model

87
Finite Element model for Cross 3500 x 2000 x 2565 - RAS Laffan

Finite Element model of

1600 x 2500 TEE

88
HEAT EXCHANGER HEAD
• Tube & Shell type Heat Exchanger head in seawater
application
• Advantage of GRP
– High corrosion resistance
– Easy to manufacture
– Low costs as compared to
stainless steel, Duplex or
more exotic materials

89
90
Comparison Study for GRP and Metal Evaporator
Header Box

Typical Finite element stress results for GRP (left) end metal (right).

• Note the higher stress levels for metal

• Flange loads in GRP are lower than in metal
• Lower costs of GRP box
• No corrosion in GRP Box

PREDICTION & VERIFICATION

• Glass Reinforced Plastics fail due to excess of strain
• Macroscopic displacements are directly related to strain
• FE-calculations predict displacements
• Displacements are relatively easy to measure during test and/or in the field

Prediction of displacements of a complex cross shape, verified during

pressure test

91
MEASUREMENT DURING TEST
Displacement Measurements

92
CASE STUDIES

93
RAS LAFFAN COMMON COOLING SEAWATER
SYSTEM PHASE II – CATEGORY II PROJECT

Project Synopsis
The Ras Laffan Common Cooling Seawater System Phase II is a development
being undertaken by Qatar Petroleum for providing cooling water supply to
Industries located in Ras Laffan city, State of Qatar. The Phase II expansion of
Ras Laffan Common Cooling Water System is based on a combination of re-
circulating seawater cooling towers located within battery limit of some of the
end users and once through system for other end users.

The cooling seawater will be processed to filter out refuses down to 3mm, dosed
with sodium hypochlorite and then pressurised/pumped to required battery limit
pressure for distribution to consumer industries through GRP pipelines.

The return of the seawater is similar to the supply and comprise of GRP Pipelines
forming common headers which are connected to the end users. The return
cooling water pipes discharge into the receiving basin structure. From the
receiving basin the water flows over a series of weirs into a discharge channel
to the sea over the out fall structure.

The seawater filtration equipment, main cooling seawater pump sets and utility
plant facilities including electro chlorination unit will is fire protected by fresh
water GRE fire water fighting system.

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FPI Scope
• Engineering, Isometric drawings, BOM, stress analysis, FEM and support
design
• Fabrication and spooling of customized fittings
• Extensive qualification testing as per ISO 14692
• Packing and delivery to jobsite
• Documentation, method statements and project management
• Training, Installation, Testing and Commissioning supervision and technical
advisory

Pipe System
The pipe system was designed and manufactured in accordance with ISO
14692 code with the below approximate quantities:
• 80 kms of GRP from 700mm up to and including 4000mm for all the
sweater cooling lines
• 25 kms GRE/GRV from up to 600mm for the sweater, firewater and potable
water lines

FPI’s WAVISTRONG™ & FIBERSTRONG™ as the

“MATERIAL OF CHOICE’’
In 2002, Phase I of this project built from Glass flake lined Carbon Steel
pipelines proved its incapability to sustain the highly corrosive environment of
the seawater medium and developed a high rate of leakage throughout the pipe
length during its installation and commissioning. The client QP then needed to
explore, on a relatively smaller scale project, the use of an alternative material
‘’ Fiberglass’’ and executed that in Phase I extension project. The project was
completed by M/s CCIC in 2006 involving around 18 kms of GRP pipes in
diameters up to 2800mm supplied by FPI. To everyone’s expectations, the
GRP pipe system successfully proved its performance for the project design
parameters.

95
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100
Barwa Commercial Avenue Pre-Insulated
GRP Pipe System for Chilled Water

• Location: Industrial Highway (Abu Hamour Road), Doha, Qatar.

• End User: BARWA
• Main Client: Hochtief Qatar
• Contractor: MACE Qatar
• Consultant: Maunsell Consultancy Services
• Project Purpose: Underground Pre-Insulated Chilled Water Piping System
• Diameter Range: 250 mm Up to 750 mm
• Total Length: Approximately 14 kilometers of Supply & Return Lines
• Pressure: 16 Bar for the Supply Line and 10 Bar for the Return Line
• Scope: Preparation of Isometric Drawings with detailed BOQ, Stress & Surge
Analysis, Manufacture, Pre-insulation of Chilled Water Piping, Testing,
Delivery to Site.

101
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103
104
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INSTALLATION

106
UNDERGROUND PIPING SYSTEM

107
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125
126
127
128
129
130
131
132
133
134
ABOVEGROUND PIPING SYSTEM

135
136
137
138
SEAWATER INTAKE OUTFALL SYSTEM

36 meter pipe section is being lifted on shore ready for placement on a barge

139
36 meter pipe section is being lifted on shore ready for placement on a barge

140
141
Installation using crushed rocks as backfill

142
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OIL & GAS SYSTEM

Yellow Box

Yellow Box

147
Yellow Box

Yellow Box

148
Yellow Box

Yellow Box

149
Red Box

Red Box

150
Red Box

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MARINE SYSTEM

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© Copyright Future Pipe Industries Group 2011, All rights reserved.
www.futurepipe.com